Ian-

Sounds like you are okay. Remember, a CV isn't designed to provide
"extension and contraction" as much as it is to transfer power at an angle.
The extension and contraction of the joint is somewhat of a by-product; to
absorb differences in the distances between the transmission output shaft,
and the wheel/axle hub as the wheel moves up and down over the road
surface.

Some slight irregularities in the machining or wear of the joints at their
outer limits are not uncommon. As the tolerances are tight, a very slight
taper or ridge at the end of the machined groove in the join would cause
the ball to bind. No big.

G. Matthew Bulley
Bulley-Hewlett & Associates
www.bulley-hewlett.com
Cary, NC USA
888.468.4880 tollfree

-----Original Message-----
From:   Ian Cameron [SMTP:ianc@UVIC.CA]
Sent:   Saturday, July 03, 1999 9:22 PM
To:     vanagon@GERRY.VANAGON.COM
Subject:        CV Joint advice

The other day my van started making a noise that I figured was either CV
joints or rear wheel bearings.  As the joints seemed easiest to fix, and
only the PO knows when they were last done, I decided to have a shot.  Got
them off all right, and one seemed pretty dry (two more a bit dry but not
bad, and one just fine) but couldn't separate the joint from the shaft.  So
I figured I'd leave it on, clean it up, and inspect it still on the shaft.
I got it clean, but as I was wiping off the last of the old grease the damn
thing came apart in my hands.  According to Haynes taking it apart requires
that it be off the shaft.  Not so.  Everything was fine, so I put it
together (finally) and greased it.  Now it isn't as easy to manipulate as
the others.  It slides in and out easily to full extension, and works
easily in the middle of the range, but at full extension it sticks
momentarily as I flex it to the extreme positions.  The others don't do
that.  It's together properly, according to the others and the book.  Any
comments, or do I wait until Monday and take it to the expert?